SHAPER

Shaper is a reciprocating type of machine tool in which the ram moves the
cutting tool
backwards and forwards in a straight line.
It is intended primarily to produce flat surfaces. These surfaces may be
horizontal,
vertical, or inclined. In general, the shaper can produce any surface
composed of straight-line
elements.
Base
It is rigid and heavy cast iron body that supports all other parts of the
machine, which are mounted over it. The base may be rigidly bolted to the
floor of the shop or on the bench according to the size of the machine.
Column
The column is a box shaped casting mounted upon the base. It houses the
ram-driving
mechanism. Two accurately machined guide ways are provided on the top of
the column on
which the ram reciprocates.
Cross rail
It is mounted on the front vertical guide ways of the column.
It consists mechanism for raising and lowering the table to accommodate
different sizes of
jobs by rotating an elevating screw which causes the cross rail to slide up
and down on the
vertical face of the column. A horizontal cross feed screw is fitted within the
cross rail and
parallel to the top guide ways of the cross rail. This screw actuates the table
to move in a
crosswise direction.
Saddle
The saddle is located on the cross rail and holds the table on its top.
Crosswise movement
of the saddle by rotation the cross feed screw by hand or power causes the
table to move
sideways.
Table
The table is a box like casting having T -slots both on the top and sides for
clamping the
work. It is bolted to the saddle and receives crosswise and vertical
movements from the
saddle and cross rail.
Ram
It is the reciprocating part of the shaper, which reciprocates on the
guideways provided
above the column. Ram is connected to the reciprocating mechanism
contained within the
column.
Tool head
The tool head of a shaper performs the following functions-
(1) It holds the tool rigidly,
(2) It provides vertical and angular feed movement of the tool, and
(3) It allows the tool to have an automatic relief during its return stroke.
The various parts of tool head of shaper are apron clamping bolt, clapper
box, tool post,
down feed, screw micrometer dial, down feed screw, vertical slide, apron
washer, apron swivel
pin, and swivel base. By rotating the down feed screw handle, the vertical
slide carrying the
tool gives down feed or angular feed movement while machining vertical or
angular surface.
The amount of feed or depth of cut may be adjusted by a micrometer dial on
the top of the
down feed screw. Apron consisting of clapper box, clapper block and tool
post is clamped upon
the vertical slide by a screw. The two vertical walls on the apron called
clapper box houses
the clapper block, which is connected to it by means of a hinge pin. The tool
post is mounted
upon the clapper block. On the forward cutting stroke the clapper block fits
securely to the
clapper box to make a rigid tool support. On the return stroke a slight
frictional drag of the
tool on the work lifts the block out of the clapper box a sufficient amount
preventing the tool
cutting edge from dragging and consequent wear. The work surface is also
prevented from
any damage due to dragging.

WORKING PRINCIPLE OF SHAPER

A single point cutting tool is held in the tool holder, which is mounted
on the ram. The
workpiece is rigidly held in a vice or clamped directly on the table. The table
may be
supported at the outer end. The ram reciprocates and thus cutting tool held
in tool holder
moves forward and backward over the workpiece.
In a standard shaper, cutting of material takes place during the
forward stroke of the ram. The backward stroke remains idle and no cutting
takes place during this stroke. The feed is given to the workpiece and depth
of cut is adjusted by moving the tool downward towards the workpiece. The
time taken during the idle stroke is less as compared to forward cutting
stroke and this is obtained by quick return mechanism. The cutting action
and functioning of clapper box is shown in Fig.23.4 during forward and return
stroke.
TYPES OF SHAPERS
Shapers are classified under the following headings:
(1) According to the type of mechanism used for giving reciprocating motion
to the ram
(a) Crank type
(b) Geared type
(c) Hydraulic type
(2) According to the type of design of the table:
(a) Standard shaper
(b) Universal shaper
(3) According to the position and travel of ram:
(a) Horizontal type
(b) Vertical type

23.3.1 Crank Shaper

This is the most common type of shaper. It employs a crank mechanism to
change
circular motion of a large gear called “bull gear” incorporated in the machine
to reciprocating
motion of the ram. The bull gear receives power either from an individual
motor or from an
overhead line shaft if it is a belt-driven shaper.

SPECIFICATION OF A SHAPER
The size of a shaper is specified by
 the maximum length of stroke or cut it can make.
 the type of drive (belt drive or individual motor drive),
 floor space required,
 weight of the machine,
 cutting to return stroke ratio,
 number and amount of feed,
 power input

SHAPER MECHANISM
In a shaper, rotary motion of the drive is converted into reciprocating motion
of the ram
by the mechanism housed within the column or the machine. In a standard
shaper metal is
removed in the forward cutting stroke, while the return stroke goes idle and
no metal is
removed during this period as shown in Fig. 23.4. The shaper mechanism is
so designed that
it moves the ram holding the tool at a slower speed during forward cutting
stroke, whereas during the return stroke it allow the ram to move at a faster
speed to reduce
the idle return time. This mechanism is known as quick return mechanism.
The reciprocating
movement of the ram and the quick return mechanism of the machine are
generally obtained
by anyone of the following methods:
(1) Crank and slotted link mechanism
(2) Whitworth quick return mechanism, and
(2) Hydraulic shaper mechanism
The crank and slotted link mechanism is discussed as under.
23.6.1 Crank and Slotted Link Mechanism
In crank and slotted link mechanism (Fig. 23.6), the pinion receives its
motion from an
individual motor or overhead line shaft and transmits the motion or power to
the bull gear.
Bull gear is a large gear mounted within the column. Speed of the bull gear
may be changed
by different combination of gearing or by simply shifting the belt on the step
cone pulley. A
radial slide is bolted to the centre of the bull gear. This radial slide carries a
sliding block
into which the crank pin is fitted. Rotation of the bull gear will cause the bush
pin to revolve
at a uniform speed. Sliding block, which is mounted upon the crank pin is
fitted within the
slotted link. This slotted link is also known as the rocker arm. It is pivoted at
its bottom end
attached to the frame of the column. The upper end of the rocker arm is
forked and connected
to the ram block by a pin. With the rotation of bull gear, crank pin will rotate
on the crank
pin circle, and simultaneously move up and down the slot in the slotted link
giving it a
rocking movement, which is communicated to the ram. Thus the rotary
motion of the bull
gear is converted to reciprocating motion of the ram.
SURFACES PRODUCED ON SHAPER
1. Horizontal plain surface
2. Vertical plain surface
3. Inclined surface
4. Grooved surface
5. Slotted surface
6. Stepped surface

SHAPER OPERATIONS
A shaper is a machine tool primarily designed to generate a flat surface by a
single point
cutting tool. Besides this, it may also be used to perform many other
operations. The different
operations, which a shaper can perform, are as follows:
1. Machining horizontal surface (Fig. 23.7)
2. Machining vertical surface (Fig. 23.8)
3. Machining angular surface (Fig. 23.9)
4. Slot cutting (Fig. 23.10)
5. Key ways cutting (Fig. 23.11)
6. Machining irregular surface (Fig. 23.12)
SPEEDs and feeds

length of cutting stoke , L

Cutting speed ,V = …………….. (i)
Time required by cutting stroke

Let L = length of cutting stroke

m = the ratio between return time to cutting time
n = the number of double stroke of Ram per minute or RPM of bull gear
V = cutting speed m/min (from equation i)
 Simpler method
Cutting stroke and return stroke are not equal thus approximate method is
used to set the machine
Divide twice the length of stroke in meters into the lowest allowable cutting
speed (for turning on lathe) for the given material of workpiece. This will give
the number of double strokes of the ram per minute
Efg for shaping mild steel on a ¼ meter stroke, and taking cutting speed of
20meters per minute:
Number of machine cycles (double strokes) = 20/(2 x ¼ ) = 40 double
strokes per minute

Feed

The feeding mechanism on many shaping machines consists of a ratchet

wheel keyed to the table leadscrew, and actuated by a swinging pawl which
oscillates under the action of a connecting rod, the end of which is given an
eccentric motion from a rotating flange on the side of machine.
With such a mechanism the choice of feeds is rather limited, since the
greatest movement of the pawl is such as to give up to about four teeth on
the ratchet wheel. In general, it will be found that for most jobs one or two
teeth of the wheel will prove satisfactory, but the reader should work out for
himself the value of the feed given when the ratchet wheel is being indexed
by a single tooth. Thus, if the ratchet wheel has, say, 28 teeth and the table
lead-screw a pitch of 5 mm:
Feed for 1 tooth = 1/28 x 5 = 5/28 mm = about 0.18 mm per stroke.
It should be remembered that the feed of the tool should occur during the
return stroke

Checking the Vice Jaws for Squareness and Parallelism

For checking the vice jaws for its squareness, place dial test indicator in the tool holder so that
the indicator touches the finished surface. Then move the table with the help of cross feedback
& forth and note the variation on the indicator.

Setting the Length of Stroke

The following procedure is to be adopted while setting the length of the stroke.
(a) Bring the ram to the rear most position.
(b) Loosen the knurled nut.
(c) Turn the crank (stroke adjusting crank) till the desired length of the stroke length of job +
3/4" (1/4" front clearance+1/2" back clearance)
(d) Tighten the knurled nut.

Position of Tool
The following procedure is to be adopted while positioning the tool:
(a) Bring the ram to the rear most position.
(b) Loosen the ram clamp.
(c) Turn the crank (until the tool is a little distance away from the work)
(d) Tighten the ram clamp.

Normally the tool clearance should be more at the rear end of the job than of the front end so
that the tool block is enabled to be set properly for the next cut. The tool holder is to be set so
that the tool bit does not extend more than about 2" from the tool post. The overhanging of
the tool and tool slide should be as less as possible for rigidity. The tool head and the cutting
tool should be vertical and the clapper box turned away from the direction to which
it is being fed .This position of the clapper box prevents the tool from digging into the work and
it will swing away from the finished surface on the return stroke
Precautions to be Observed while Shaping Jobs
(a) The alignment of the workpiece is to be checked (whether it is parallel to the movement of
the ram) and adjusted before starting the work.
(b) suitable stroke ie not too long and not too short
(c) clearance of tool from each end of workpiece

Work holding devices

- Plain or parallel vice
- Swivel machine vice
- Universal vice
- Vertical/vice
- Rotary table

Shaper cutting tools

The material of the cutting tool used in a shaping machine should have more
hardness and temper when compared to the material of the workpiece. So,
the shaper tools are made of the following materials
1. High Carbon Steel
2. High Speed Steel
3. Carbide tipped tool
4. Stellite tool

Types of Shaper Tools

According to the type of work and the type of operation, various tools are
used in a shaper.
They are
Right hand ( R. H ) tool – This is a tool used for machining by moving
the job from right to the left.
Left hand ( L. H ) tool – This is a tool used for machining by moving the
job from left to right.
Roughing tool – When it is required to remove a good amount of
material from the workpiece, roughing tools are used. The cutting edge will
be very thick, sharp and strong to withstand the cutting pressure and to
dissipate the heat generated at the cutting point. The surface obtained will
be very rough.
Finishing tool – After the rough machining is performed, the finishing
tool is used to obtain a very high quality of surface finish. The cutting edge
will be either flat or slightly convex.
Goose neck tool – This is a special type of tool used for finish
machining. Very good surface finish will be obtained. The cutting edge of
goose neck tool has a springy action. The tip of the cutting edge lies in the
same line with the rear side of the shank.
Slot cutting tool – Wide rectangular or square grooves are known as
slots. Rough machining of the slot is carried out using round nose tool. After
that, a slot cutting tool is used for finish machining work.